Claas Nexos 240-210 Md Stage V (A71) Tractors Repair Manual EN

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00 1173 933 X.pdf
00 1177 721 X.pdf

00 1173 933 X.pdf:

NEXOS 210Stage V
Table of contents
CCN (CLAAS Component Number)
Introduction
General information
Using this repair manual
Validity of this repair manual
General repair instructions
Technical specifications
Cause of damage
Spare parts
Diesel engine
Alternator
Welding work
Drive belt/drive chains
Tapered ring assemblies
Self-locking bolts with microencapsulated glue
Threadlock
Lock collar bearing
Collet bearing
Threaded unions with cutting rings on the hydraulic hoses
Threaded unions with progressive rings on the hydraulic hoses
Threaded double flare unions on the hydraulic hoses
Flexible hydraulic pipes
Pipe routing
Advice for economical repairs
Tightening torques
Tightening torques for CN02-0220 2002-09-26 factory standard metric threads
Tightening torque for bolts
Tightening torque for DRH lock nuts
Tightening torque for Nylstop lock nuts
Tightening torques for CLAAS CN 02 0225 standard hydraulic connections
Tightening torques for hydraulic threaded unions and air conditioning threaded unions with sealing cone and DIN 3865 O-ring
Tightening torques for DIN 3901 hydraulic threaded unions
Tightening torques for ISO 6149-2/ISO 11926-2 (3) adjustable hydraulic threaded unions
Tightening torques for hydraulic swivel threaded unions
Tightening torques for quick connection cartridges
Tightening torques for DIN 8434 hydraulic threaded bulkhead connectors
Tightening torques for DIN 7643 hollow bolts
Technical specifications
Lubricants
01 Engine
0102 Complete component
Introduction
General notes
Complete engine
Technical specifications
Special tool
Coupling the engine to the chassis
Technical specifications
Preparation for work
Dismantling the engine
Dismantling
Removing the cylinder head
Assembling the engine
Assembly
Checks and inspections
0110 Engine housing
Oil sump
Technical specifications
Timing gear train housing
Technical specifications
Preparation for work
Special tool
Fitting the timing cover
Fitting the cover
Fitting the front bearing seal
Flywheel housing
Technical specifications
Preparation for work
Special tool
Fitting the rear bearing seal
Repairing the cylinder block
Dimensional specifications
Checks and measurements
Checking the supporting surface of the cylinder head on the cylinder block
0115 Engine unit
Crankshaft
Technical specifications
Dimensional specifications
Measuring the journals and crank pins
Crankshaft journals and crank pins – Measured values
Replacing the crankshaft front pinion
Fitting the bearing half-shells
Checking the lateral play
Crankshaft pulley
Technical specifications
Connecting rod and piston assembly
Technical specifications
Dimensional specifications
Special tool
Dismantling
Checking the piston
Pairing the shaft and the piston
Piston rings
Checking the piston rings
Checking the links
Torsion check
Flexion check
Fitting the connecting rod and piston assembly – Coupling the connecting rod and piston
Fitting the piston rings
Fitting the connecting rod and piston into the cylinder
Fitting the connecting rod caps
Piston protrusion measurement
Balancer
Technical specifications
Special tool
Flywheel
Technical specifications
0120 Cylinder head / Valves / Idler gear
Cylinder head
Technical specifications
Dimensional specifications
Sealing check
Checking the cylinder head contact surface
Checking the cylinder head contact surface (cylinder block)
Dimensional specifications
Special tool
Cleaning and checking the valves
Checking the clearance between the valve stems and the valve guide and centring the valves
Checking the valve springs
Checking and replacing the valve guides
Checking the valve guide
Replacing the valve guide
Valve guide bore
Checking and replacing the valve seats
Checking the valve withdrawal
Rocker cover
Technical specifications
Rocker arm ramp
Technical specifications
Dimensional specifications
Camshaft
Technical specifications
Dimensional specifications
Special tool
Checking the cam lift and the alignment of the shaft bearings
Replacing the rings
Fitting the valve lifters
Timing pinions
Technical specifications
Special tool
Camshaft and crankshaft timing
Adjusting the high-pressure pump and the crankshaft
0125 Injection / Fuel system
Main fuel tank on NEXOS LD and MD
Low-pressure fuel pipes
Technical specifications
Technical specifications
Connections
Fuel pre-filter and cooler
Technical specifications
High pressure pump
Technical specifications
Special tool
Common rail
Technical specifications
Injectors
Technical specifications
Fuel cooler
0130 Lubricating oil system
Engine oil filter
Technical specifications
Oil pump
Technical specifications
Oil pressure controller
Technical specifications
Relief valve
Technical specifications
Engine oil heat exchanger
Technical specifications
Oil vapour filter (Recirculation of oil vapours)
Technical specifications
0135 Cooling system
Engine water radiator
Drive belts
Main drive belt
Special tool
Checking the tension of the main drive belt
Ventilation
Technical specifications
Water pump
Technical specifications
Thermostat
Technical specifications
0140 Exhaust system
Exhaust pipe on NEXOS LD and MD
Exhaust pipe on NEXOS L, M and S
Removing the vertical exhaust pipe
Removing the horizontal exhaust pipe
Turbocharger
Technical specifications
Exhaust manifold
Technical specifications
0145 Air intake
Air filter on NEXOS LD and MD
Air filter on NEXOS L, M and S
Intake manifold
Technical specifications
Technical specifications
0150 Engine attachment parts
Alternator
Technical specifications
Electric starting motor
Technical specifications
Technical specifications
0155 Engine control
ECM engine control module
Technical specifications
Engine wiring harness
Technical specifications
Pre-heater plugs
Technical specifications
Preliminary operations
0165 Exhaust gas aftertreatment
Exhaust filter on NEXOS LD and MD
Exhaust filter on NEXOS L, M and S
Technical specifications
Exhaust filter support
EGR valve
Technical specifications
02 Gearbox / Clutch / Universal drive shaft
0202 Complete component
Separating the engine and clutch housing with a fixed front axle on NEXOS LD and MD
Technical specifications
Special tool
Separating the engine and clutch housing
Immobilising the front axle
Separating the engine and clutch housing with a fixed front axle on NEXOS L, M and S
Technical specifications
Special tool
Separating the engine and clutch housing
Draining the transmission oil
Removing the first pipe
Removing the second pipe
Installing the trolley underneath the tractor
Immobilising the front axle
Removing the mounting bolts
Separating the elements
Separating the engine and clutch housing with a suspended front axle on NEXOS L, M and S
Technical specifications
Special tool
Separating the engine and clutch housing
Draining the transmission oil
Removing the first pipe
Removing the second pipe
Removing the mounting bolts
Separating the elements
Upper and lower covers
Technical specifications for the lower cover
Technical specifications for the upper cover
Preparation for work
0215 Mechanical clutch
Adjusting the clutch
11 inch clutch
Adjustment
12 inch clutch
Adjustment
Clutch for REVERSHIFT transmission with rear power take-off with mechanical clutch
Adjustment
0218 Clutch control
Reverser and clutch controls – 12/12 transmission
Technical specifications
Preparation for work
Reverser and clutch controls – 24/24 transmission (Mechanical reverser and doubler)
Technical specifications
Dimensional specifications
Preparation for work
Adjusting the axial play
Reverser and clutch controls – 24/12 transmission — Hydraulically controlled power take-off
cpecifications
Dimensional specifications
Preparation for work
Special tool
Adjusting the axial play of the reverser shaft
Adjusting the axial play of the upper shaft
Clutch and hydraulic reverser controls – 24/12 and 24/24 transmission — Mechanically-controlled power take-off
Technical specifications
Dimensional specifications
Preparation for work
Special tool
Adjusting the axial play of the reverser shaft
Adjusting the axial play of the upper shaft
Hydraulic control unit – “Gérotor” pump
Technical specifications
Dimensional specifications
Preparation for work
Special tool
Removing the hydraulic control unit
Fitting the hydraulic control unit
Removing the Gérotor pump
Fitting the Gérotor pump
0220 Mechanical reverser
Controls – Mechanical reverser
Technical specifications
Dismantling
Assemronised i Technical specifications
Dismantling
Assembly
0222 Hydraulical reverser
Hydraulic reverser
Technical specifications
Preparation for work
Special tool
Dismantling
Assembly
Adjusting the release play
Wear to the packets of discs
Hydraulic reverser idle gear
Technical specifications
Dimensional specifications
Dismantling
Assembly
0228 Reverser control
Mechanical reverser controls on NEXOS LD and MD
Adjusting the mechanical reverser
Adjustment
Mechanical reverser controls on NEXOS L, M and S
Adjusting the mechanical reverser
Adjustment
0230 Mechanical gearbox
Input shaft – Transmission with mechanical reverser
Technical specifications
Dimensional specifications
Input shaft – Transmission with hydraulic reverser
Technical specifications
Dimensional specifications
Dismantling
Assembly
Primary shaft – Gears – Transmissions with mechanical reverser
Technical specifications for a 24 x 24 transmission
Technical specifications for a 12 x 12 transmission
Dimensional specifications
Special tool
Adjusting the axial play of the primary shaft
Primary shaft – Gears – Transmission with hydraulic reverser
Technical specifications
Dimensional specifications
Adjusting the axial play of the primary shaft
Primary shaft – Ranges
Technical specifications
Dimensional specifications
Secondary shaft – Ranges
Technical specifications
Special tool
Disassembly
Assembly
Secondary shaft – Gears
Technical specifications
Dimensional specifications
Special tool
Disassembly
Assembly
Adjusting the axial play of the secondary shaft – Gears
Primary shaft covers
12on – Cross-section
mission with mechanical reverser and doubler – Cross-section
24/24 transmission with hydraulic reverser and mechanical doubler – Cross-section
24/12 transmission with hydraulic reverser and doubler – Cross-section
Mechanical doubler with mechanical reverser
Technical specifications
Dimensional specifications
Mechanical doubler with hydraulic reverser
Technical specifications
Dismantling
Assembly
0234 Powershift gearbox
Hydraulic doubler
Technical specifications
Special tool
Dismantling
Assembly
Adjusting the play
Wear to the packets of discs
0238 Gearbox control
External controls
Technical specifications
Preparation for work
Internal controls
Technical specifications
Dismantling
Forward/reverse gear or doubler
Assembly
ear axle housing
Axle tube and finves for NEXOS LD and NEXOS L
Technical specifications
Special tool
Adjusting the axial play
Axle tube and final drives for NEXOS MD and NEXOS M
Technical specifications
Dismantling
Assembly
Tapered roller bearings preload
Axle tube and final drives for NEXOS S
Technical specifications
Dismantling
Assembly
Tapered roller bearings preload
0242 Differential
Rear axle differential
Technical specifications
Preparation for work
Dismantling
Assembly
Differential lock control
Technical specifications
Preparation for work
0248 Rear axle control
Transmission sensors
Technical specifications
Applicability of the transmission sensors
Description
0250 Mechanical front axle drive
Hydraulic front axle clutch
Technical specifications
Special tool
0252 Electro-hydraulical front axle drive
Front axle hydraulic clutch
Technical specifications
Special tool
0255 Gearbox cooling system
Oil cooler on NEXOS LD and MD
Oil cooler on NEXOS L,S and M
0260 Universal drive shaft
Fixed front axle transmission shaft on NEXOS LD and MD
Fixed front axle transmission shaft on NEXOS L, M and S
Suspended front axle transmission shaft
03 Chassis
0310 Axle
Recommendations – Servicing and repair
Shaft seals
Adjustment shims
Roller bearings
Caps and rivets
Plastic protections and caps
Cotter pins
Adhesives and sealing products
Oil drain
Cleaning
Ends of flanges and special tools
Using lubricants
0320 Steering axle
Steering actuator (two-wheedrive)
Technical specifications
Repairing the steering actuator
Technical specifications
Dismantling
Assembly
Wheel hub
Technical specifications
Preparation for work
Wheel pivot
Technical specifications
Preparation for work
Axle body
Technical specifications
Adjusting the alignment and the steering angle
Technical specifications
Adjusting the alignment
Adjusting the steering angle
0325 Front steering drive axle
Steering actuator
Technical specifications
Preparation for work
Dismantling
Assembly
Steering angle sensor
Technical specifications
Preparation for work
Special tool
Epicyclic reduction unit on NEXOS L and LD
Technical specifications
Epicyclic reduction unit on NEXOS M and MD
Technical specifications
Epicyclic reduction unit on NEXOS S
Technical specifications
Special tool
Wheel hub on NEXOS L, LD and M
Technical specifications
Preparation for work
Special tool
Wheel hub on NEXOS MD
Technical specifications
Preparation for work
Special tool
Wheel hub on NEXOS S
Technical specifications
Preparation for work
Special tool
Seal – Bearing assembly – Support on NEXOS L and LD
Technical specifications
Flange on NEXOS L and LD
Technical specifications
Special tool
Flange on NEXOS M, MD and S
Technical specifications
Special tool
Differential housing on NEXOS L, M and LD
Technical specifications
Tecal specifications for NEXOS LD
Technicalcifications for NEXOS L
Technical specifications for NEXOS M
Preparation for work
Special tool
Checking the preload if the roller bearings have not been replaced
Checking the preload if the roller bearings are new
Alternative preload checking procedure
Adjusting the preload
Checking the contact imprint of the differential teeth
Differential housing on NEXOS MD and S
Technical specifications
Technical specifications for NEXOS MD
Technical specifications for NEXOS S
Preparation for work
Special tool
Adjusting the clearance between the teeth
Checking the preload if the roller bearings have not been replaced
Checking the preload if the roller bearings are new
Alternative preload checking procedure
Adjusting the preload
Checking the contact imprint of the differential teeth
Differential on NEXOS L and LD
Technical specifications
Preparation for work
Differential on NEXOS M, MD and S
Technical specifications
Preparation for work
Dismantling
Assembly
Drive pinion
Technical specifications
Special tool
Checking the preload if the roller bearings have not been replaced
Checking the preload if the roller bearings are new
Alternative preload checking procedure
Front axle body on NEXOS L, LD and M
Technical specifications
Special tool
Front axle body on NEXOS MD and S
Technical specifications
Special tool
Adjusting the alignment and the steering angle
Technical specifications
Technical specifications for NEXOS L
Technical specifications for NEXOS LD
Technical specifications for NEXOS M
Technical specifications for NEXOS MD
Technical specifications for NEXOS S
Adjusting the alignment
Adjusting the steering angle
0325 Front steering drive axle
Suspended front axle
Position sensor connecting rod
Adjustment
Suspended front axle guides
Front axle suspension cylinders
Suspended front axle position sensor
Technical specifications
Suspended front axle suspension arm
Suspended front axle articulated support roller bearing
Technical specifications
Hydraulic suspension module
Front axle suspension module
Front axle suspension calibration
Front axle suspension calibration button
Front axle suspension calibration procedure
Calibration
04 Brake
0405 Service brake
Brake mechanism
Technical specifications
Dimensional specifications
Slave cylinder
Technical specifications
Brake master cylinders
Bleeding the brake circuit on NEXOS LD and MD
Technical specifications
Technical specifications (Italy)
Preparation for work
Bleeding the brake circuit
Bleeding the trailer brake valve (option)
Bleeding the brake circuit on NEXOS L, MD and S
Technical specifications
Preparation for work
Bleeding the brake circuit
0415 Parking brake
Parking brake
Technical specifications
On either side of the transmission housing
Handbrake control
Technical specifications
Method to adjust the control
0425 Trailer hydraulic brake
Trailer hydraulic brake on NEXOS LD and MD
Components of the hydraulic trailer brake system
Trailer hydraulic brake on NEXOS LD and MD (Italy)
Components of the hydraulic trailer brake system
Trailer hydraulic brake on NEXOS L, M and S
05 Steering
0505 Steering
Steering unit
06 Lift device
0605 Rear power lift
Linkage cover
Technical specifications
Preparation for work
Specifications
Identifying the product
Description
Main components of the linkage
Technical specifications
Main dimensions
Performance
Rear linkage settings
Rear linkage sensitivity adjustment valve
Position control lever
Draft control lever
Adjusting the force return bar
Adjusting the end of travel position sensor
Setting the shock valve pressure
Special tool
Adjustment
Assembling the reaction spring
Internal push bar
Linkage actuator and arm
Technical specifications
Rear linkage control rod linkage
Technical specifications
Rear linkage main control
Rear linkage plastic ring
Technical specifications
Preliminary operations
Position control lever ring
Draft control lever ring
Position and draft control rod linkage
Technical specifications
Rear linkage spool valve
Technical specifications
Solenoid valves
Non-return valve
Pressure balance
Rear linkage shock valve
08 Drives
0802 Rear PTO
Rear power take-off hydraulic clutch and cover
Technical specifications
Special tool
Rear power take-off clutch
Wear to the packet of discs
Speed selector with a mechanical power take-off clutch
Technical specifications
Preparation for work
Special tool
Speed selector with a hydraulic power take-off clutch
Technical specifications
Preparation for work
Special tool
Only for 24/12 transmissions.
Only for 24/12 transmission
All transmission types
Only for 24/12 transmission
All transmission types
Adjusting the rear power take-off mechanical clutch stop
Input shaft
Technical specifications
Only without proportional power take-off
All power take-off types
Only without proportional power take-off
All power take-off types
Output shaft
Technical specifications
Power take-off brake
Technical specifications
Power take-off proportional to ground speed
Technical specifications with a hydraulic control
Technical specifications with a mechanical control
Operation of the power take-off proportional to ground speed
Rear power take-off sensors
Technical specifications
09 Hydraulic system
0915 Hydraulic lines
Hydraulic oil filters on NEXOS LD and MD
Hydraulic oil filters on NEXOS L, M and S
0920 Valves
Auxiliary control valves and levers on NEXOS LD and MD
Auxiliary spool valves
Auxiliary control valves and levers on NEXOS L, M and S
Auxiliary spool valves
Pressure limit valve
Technical specifications
Cleaning
Rear linkage spool locking
Technical specifications
10 Electrical / Electronic equipment
1005 Power supply
Battery on NEXOS LD and MD
Battery on NEXOS L, M and S
Battery isolating switch
ON position
OFF position
Remove the battery isolating switch
1035 Operation / Multifunction control lever
Lifting control panel
12 Cab / Operator’s platform
1205 Cab suspension
Platform cab support on NEXOS LD and MD
Front cab support mounting
Rear cab support mounting
Cab support on NEXOS L, M and S
Preparation for work
Front cab support mounting
Rear cab support mounting
1210 Cab
Complete cab on NEXOS L, M and S
Special tool
Platform cab on NEXOS LD and MD
Special tool
Trim for the platform cab levers on NEXOS LD and MD
Removing the right-hand side control panel trim
Removing the left-hand side control panel trim
Lever trims on NEXOS L, M and S
Removing the right-hand side control panel trim
Removing the left-hand side control panel trim
Rear screen wiper
1240 Air condition
Air conditioning compressor
Special tool
Removing the compressor
80 Various components / Machine body
8025 Panellings / Hoods
Engine bonnet on NEXOS MD and LD
Engine bonnet on NEXOS L, M and S
Bonnet side panels on NEXOS MD and LD
Bonnet side panels on NEXOS L, M and S

00 1177 721 X.pdf:

Repair manual
Table of contents
CCN (CLAAS Component Number)
Introduction
General information
Using this repair manual
Validity of this repair manual
General repair instructions
Technical specifications
Cause of damage
Spare parts
Diesel engine
Alternator
Welding work
Drive belt/drive chains
Tapered ring assemblies
Self-locking bolts with microencapsulated glue
Threadlock
Lock collar bearing
Collet bearing
Threaded unions with cutting rings on the hydraulic hoses
Threaded unions with progressive rings on the hydraulic hoses
Threaded double flare unions on the hydraulic hoses
Flexible hydraulic pipes
Pipe routing
Advice for economical repairs
Tightening torques
Tightening torques for CN02-0220 2002-09-26 factory standard metric threads
Tightening torque for bolts
Tightening torque for DRH lock nuts
Tightening torque for Nylstop lock nuts
Tightening torques for CLAAS CN 02 0225 standard hydraulic connections
Tightening torques for hydraulic threaded unions and air conditioning threaded unions with sealing cone and DIN 3865 O-ring
Tightening torques for DIN 3901 hydraulic threaded unions
Tightening torques for ISO 6149-2/ISO 11926-2 (3) adjustable hydraulic threaded unions
Tightening torques for hydraulic swivel threaded unions
Tightening torques for quick connection cartridges
Tightening torques for DIN 8434 hydraulic threaded bulkhead connectors
Tightening torques for DIN 7643 hollow bolts
Technical specifications
Lubricants
01 Engine
0102 Complete component
Introduction
General notes
Complete engine
Preparation for work
Special tool
Coupling the engine to the chassis
Technical specifications
Preparation for work
Special tool
0110 Engine housing
Timing gear train housing
Technical specifications
Preparation for work
Special tool
Fitting the timing cover
Fitting the cover
Fitting the front bearing seal
Oil sump
Technical specifications
Flywheel housing
Technical specifications
Preparation for work
Special tool
Removing the rear bearing seal
Fitting the rear bearing seal
0115 Engine unit
Crankshaft
Technical specifications
Dimensional specifications
Measuring the journals and crank pins
Crankshaft journals and crank pins – Measured values
Replacing the crankshaft front pinion
Fitting the bearing half-shells
Checking the lateral play
Crankshaft pulley
Technical specifications
Connecting rod and piston assembly
Technical specifications
Dimensional specifications
Special tool
Dismantling
Checking the piston
Pairing the shaft and the piston
Piston rings
Checking the piston rings
Checking the links
Torsion check
Flexion check
Fitting the connecting rod and piston assembly – Coupling the connecting rod and piston
Fitting the piston rings
Fitting the connecting rod and piston into the cylinder
Fitting the connecting rod caps
Piston protrusion measurement
Balancer
Technical specifications
Special tool
Flywheel
Technical specifications
0120 Cylinder head / Valves / Idler gear
Cylinder head
Technical specifications
Dimensional specifications
Sealing check
Checking the cylinder head contact surface
Checking the cylinder head contact surface (cylinder block)
Dimensional specifications
Special tool
Cleaning and checking the valves
Checking the clearance between the valve stems and the valve guide and centring the valves
Checking the valve springs
Checking and replacing the valve guides
Checking the valve guide
Replacing the valve guide
Valve guide bore
Checking and replacing the valve seats
Checking the valve withdrawal
Rocker cover
Technical specifications
Rocker arm ramp
Technical specifications
Dimensional specifications
Camshaft
Technical specifications
Dimensional specifications
Special tool
Checking the cam lift and the alignment of the shaft bearings